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The aim of this study was to evaluate the effect of modifying a 3D-printed denture base resin with nanozeolite particles on dimensional accuracy (DA), fracture toughness (FT), biaxial flexural strength (BFS), and surface roughness (SR).<\/jats:p>\n          <\/jats:sec>\n          <jats:sec>\n            <jats:title>Methods<\/jats:title>\n            <jats:p>Nanozeolite particles were added to 3D-printed methacrylate-based denture base resin to produce the following groups: Control, 0.25% nanozeolite, and 0.5% nanozeolite. Dimensional accuracy was assessed with a digital calliper. Fracture toughness was assessed by the single edge notched beam method (SENB) followed by Weibull analysis and work of failure. Biaxial flexural strength was tested with a universal testing machine and surface roughness was assessed with a contact profilometer. FT, BFS, and SR were assessed before and after thermal cycling of 600 cycles. Two-way ANOVA test followed by Tukey post hoc test were conducted for FT, BFS, and SR. Kruskal\u2013Wallis test was used to compare the percent error in length, width, thickness, and percent change in FT, BFS, and surface roughness among groups with subsequent Dunn post hoc test with Bonferroni correction (\u03b1\u2009=\u20090.05).<\/jats:p>\n          <\/jats:sec>\n          <jats:sec>\n            <jats:title>Results<\/jats:title>\n            <jats:p>The printing DA results revealed that the control had the highest percent error in length and width with no significant difference among the study groups, whereas the 0.5% nanozeolite group presented the highest percent error in thickness with a significant difference compared to the control. The results of FT displayed a significant statistical interaction between the resin filler content and thermal cycling (<jats:italic>P<\/jats:italic>\u2009=\u20090.001). BFS was significantly affected by the nanozeolite filler content (<jats:italic>P<\/jats:italic>\u2009&lt;\u20090.001) with the 0.25% nanozeolite group displaying the highest mean values before and after thermal cycling. The SR results revealed a statistically significant interaction between the filler content and thermal aging (<jats:italic>P<\/jats:italic>\u2009&lt;\u20090.001). The 0.5% nanozeolite group displayed the lowest SR mean values before and after thermal aging.<\/jats:p>\n          <\/jats:sec>\n          <jats:sec>\n            <jats:title>Conclusions<\/jats:title>\n            <jats:p>The addition of nanozeolite enhanced the FT, BFS, and SR, however, care should be given to the optimum percentage added to the resin to attain optimum properties which would enhance the clinical performance of the denture bases and their longevity.<\/jats:p>\n          <\/jats:sec>","DOI":"10.1186\/s12903-025-06142-8","type":"journal-article","created":{"date-parts":[[2025,5,21]],"date-time":"2025-05-21T16:09:00Z","timestamp":1747843740000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":4,"title":["Assessment of dimensional accuracy, fracture toughness, biaxial flexural strength, and surface roughness of nanozeolite reinforced 3D-printed denture base resin (In-vitro study)"],"prefix":"10.1186","volume":"25","author":[{"given":"Pansai A.","family":"Mohamed","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Omnia","family":"Ghabour","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Yomna","family":"Ibrahim","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-5802-3190","authenticated-orcid":false,"given":"Mai M.","family":"Eldokmak","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2025,5,21]]},"reference":[{"key":"6142_CR1","doi-asserted-by":"crossref","unstructured":"Mohamed PA, Ibrahim YM, Hanno KIH, Abdul\u2010Monem MM. 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